ALAQUA is a company based in the United States that supplies processing equipment worldwide. We’ve been supplying food-grade, sanitary, and ASME code evaporators, crystallizers, spray dryers, solvent recovery, and distillation systems for over 25 years. Alaqua was founded in 1989 and came to a corporation in 1993. The evaporators include falling film evaporators, rising film evaporators, plate evaporators, and various other types of processing equipment.
The liquid product normally reaches the evaporator from the top of falling film evaporators. The stock is uniformly dispersed into the heating tubes in the top head. At boiling temperature, a thin film reaches the heating tube and flows downward, partly evaporating. Typically, steam is used to fuel the evaporator. Inside the heating tubes, both the product and the vapours flow downward in a parallel flow. The gravity-induced downward acceleration is amplified by the co-current vapour wave. The vapour separator is used to separate the liquid from its vapour.
Low temperature variations between the heating media and the boiling liquid can be seen in falling film evaporators, and they have brief product touch intervals, usually measured in seconds per pass. These characteristics make the falling film evaporator ideal for heat-sensitive materials, and it is now the most commonly used evaporator type.
However, falling film evaporators must be properly configured for each working condition; adequate wetting of the heating surface by liquid is critical for the plant’s trouble-free operation. Dry patches and scaling will appear if the heating surfaces are not properly wetted; in the worst-case scenario, the heating tubes will get clogged.
To ensure complete and even product wetting of the tubing, the product delivery mechanism in the head of the evaporator must be properly designed. The falling film evaporator can be started quickly and switched to cleaning mode or another product due to the small liquid holding capacity in this sort of device.
Changes in parameters such as energy source, vacuum, feed rate, concentrations, and so on have a big impact on falling film evaporators. They will deliver a reliable focused product when fitted with a well-designed automatic control system. Since falling film evaporators can work with minor temperature variations, they can be used in multiple effect setups or in modern plants with low energy consumption mechanical vapour compression systems.
In India, there are approximately 550 sugar factories in operation, with 70 backend refineries and 6 standalone refineries. Falling film tubular evaporators with tube sizes of 35/45 mm and tube lengths ranging from 8.0 m to 12.0 m are used in about 40% of sugar factories, including sugar refineries. About 300 sugar refineries and factories use different types of falling film evaporators around the world.
Isgec has advanced the concept of a falling film evaporator by incorporating a Novel juice distributor. We all know that the most essential component of Falling Film Evaporator is the juice dealer. A bad design can be disastrous, resulting in tube clogging due to sugar caramelization, which wastes a lot of sugar and reduces performance.
The energy economy of the beet sugar business has been consistently enhanced and refined over decades in order to minimize steam use as much as possible, but the cane sugar business has placed a low priority on this issue for a long time. This mindset, however, is no longer valid. More and more cane sugar mills are closely monitoring their energy consumption numbers in order to cut steam use as much as possible by investing in equipment and optimizing processes. The current global trend of installing cogeneration facilities is the primary reason for cane sugar companies to track not only the number of bags of sugar produced daily but also the amount of bagasse saved daily. After the campaign to create electric power, the bagasse saved is used as an energy source.
Steam saving for the sugar process is required in order to obtain additional money from cogeneration. Plants with obviously less than 30% steam on the cane for the plantation white process, as well as plants with around 40% steam on the cane for the cane sugar mill with a full refinery, are already effectively operating.
In the beet sugar sector, falling film evaporators have proven to be great performers. They may also be utilized successfully in the cane sugar business, thanks to a well-designed cleaning procedure and proper discharge of non-condensable gases. Because these evaporators need a lower temperature gradient than Roberts evaporators and have a shorter residence period, the temperature in the evaporation plant’s final effects can be raised. As a result, vapour from effects 3 and even 4 may be used for crystallisation, allowing cane sugar companies to optimize their heating systems.
When falling film evaporators are combined with a well-organized sugar house operation (continuous boiling, batch pans with stirrers, and regulated water application), specific steam consumption values of 30% on the cane in cane sugar factories without a refinery and 40% on the cane in cane sugar factories with a refinery can be consistently reached.
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